Simulation modeling is a powerful tool widely used for designing construction processes and improving the efficiency of operations. However, there is often difficulty in estimating the duration of manual tasks for simulation purposes due to its dependence on the physical attributes of the worker performing the task. When designing a new process, there is usually a lack of sufficient data regarding the required duration for manual tasks, and in the case of evaluating and improving existing processes, there is no benchmark data for workers’ performance to enable comparison of the efficiency of the existing process. This study attempts to address this issue by exploring micro-motion-level simulation modeling in order to provide standard motion time required to perform a manual task for effective workplace design. The research method involves integrating a Predetermined Motion Time System (PMTS) into discrete event simulation, which provides the production planner with a standard task duration within which a worker must complete the task without delays or idling. As a case study, a manual task taking place in the production line of a construction steel fabrication company has been modeled using the developed automation tool in order to verify the feasibility of the proposed approach. The results show high correlation between the simulation model output and the actual time data from the jobsite and confirm the validity of the approach and its effectiveness in evaluating the productivity of the existing operations and providing detailed information for process improvement.

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